FTTH Cable Production: How the Manufacturing Process Works
Quick fact: in excess of seventy percent of new U.S. broadband builds now rely on fiber networks that demand tight manufacturing control to hit performance targets.
Shanghai Weiye OFC Equipment handles full-cycle compact fiber unit manufacturing, from selecting brand fibers like Fujikura or Corning® SMF-28e to complete test reports that guarantee full quality assurance.
Our drop cable designs suit aerial, underground, and direct burial installation, with LSZH, polyvinyl chloride (PVC), and PE jacket options and configurations from 1 to 4 cores. We supply single-mode OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automation and high-precision equipment keep line speed steady and maximize repeatability. Typical lead times are four to five days for orders < 100 km and seven to ten days for < 500 km, with an MOQ of 1 km and warranty for free replacement on quality issues.
Keep reading to understand how materials plus testing and support work together to reduce lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment provides end-to-end manufacturing and lab testing for U.S. deployments.
- Multiple jacket choices and fiber grades fit different install environments.
- Automated production lines ensure stable quality and stable optical performance.
- Fast lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Comprehensive test reports and after-sales warranty support product reliability and documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides tailored drop solutions with complete test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment combines specialized equipment with stringent material control. We provide customized service and products for residential and MDU rollouts. Every order includes 100% quality assurance and full test reports.
Our lab performs high heat, salt-fog, and vibration testing to verify durability. Jacket options include LSZH, PVC, and PE. Designs cover flat bow-type and self-supporting styles and support brand fibers such as Fujikura and Corning® SMF-28e.
- Controlled production lines and in-process checks for fully auditable shipments.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixtures and calibration minimize variation so every cable meets operator standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, combining brand fiber choices with strict test routines.
Fiber Selection & Brand Options
We select Fiber coloring machine to bend radius, loss, and install environment. Options include OS1/OS2 and OM2–OM4 and G.652D and G.657.A1/A2 per ITU-T. Brand fibers such as Fujikura® and Corning SMF-28e are offered to satisfy sourcing standards.
Strength Member Options
Strength members use dielectric FRP or metallic steel wire. FRP is preferred where non-conductive runs are required. Steel wire provides tensile strength for long-span aerial runs and bonding/grounding needs.
Jacket Options and Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Tight process control of temperature and capstan ratios stabilizes line speed and dimensional tolerances.
| Component | Dielectric FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Advantage | Light, non-corrosive | High strength |
| Installer note | Easier terminations | Requires grounding |
Inline and final testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify attenuation and return loss. Each order ships with a full test report and lab results from high-temperature, salt-spray, and vibration trials to confirm handling for drop terminations and field use.
Typical lead times are 4–5 days for < 100 km and 7–10 days for < 500 km. Lot records and FAI approvals support traceability and compliance for U.S. projects.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a focused portfolio of drop designs that fit indoor risers and long aerial runs. Each option combines tested materials with field-termination geometry and consistent optical performance.
The bow-type flat drop cable minimizes footprint for risers/ducts. It keeps bend loss low for easy routing in hallways and MDUs.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a messenger element to carry tensile loads. Choose dielectric FRP for non-conductive runs or steel wire when bonding and higher tensile strength are required.
Layouts & Strength Members
We offer both dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and unitube flat types balance crush resistance and compact fiber unit for quick termination.
Indoor/outdoor jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor durability. Each series is validated for mechanical and optical quality before shipment.
| Type | Best use | Strength element | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | PE |
| Central loose-tube | Higher fiber counts | FRP | LSZH/PE |
| Flat unitube | Low count, quick strip | FRP or steel | LSZH or PE |
Production Assets for Speed and Quality
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for patch cord prep.
Our production line uses automated machines that cut and strip drop patch cords to increase output and cut labor variability.
The CLX-BPO2 auto-stripping machine uses PLC + photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH and PVC jackets and trims FRP/steel members to precise reserved lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic and photoelectric sensors deliver precise positioning and feedback control. Inline checks feed control charts so operators can adjust drifts before out-of-control conditions occur.
| Feature | Capability | Benefit |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders maintain clean workcells.
- PCPs capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without sacrificing accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 provides industrial-grade strip/trim to our line, cutting cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output and standardize terminal quality. The unit cycles in ~1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC and photoelectric control deliver exact detection and repeatable actuation. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Line Speed
Typical operation speed is ~1.5 seconds per cycle. This converts to steady throughput under normal production conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable jacket strip length from 17.5–35.0 mm. Reserved strength member stubs are set between 7.0 and 11.0 mm to fit common termination hardware.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting adjacent fibers. Custom tooling are offered for non-standard cross-sections to preserve precision.
- Auto-eject scrap and sensor start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass simplify cell integration.
- Pneumatic cylinders and PLC/photoelectric control improve line reliability and lower maintenance interruptions.
| Spec | Rating | Benefit |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| Power & size | 50W @ 110–220V; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes terminal prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures every order to fit your network requirements and simplify field rollout. We pair concise options with predictable manufacturing windows so your teams get install-ready reels.
Choose 1–4 core designs with SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 along with G.652D and G.657 variants to align with optics and connector plans.
We Pantone-match sheath colors for quick field identification and consistent asset tagging.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets based on route and safety rules. Custom print legends and logos aid inventory/warranty tracking.
Length options, packaging, and special structures
Standard reel lengths are 1/2/4 km with custom reels and packaging to suit storage and handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to fit span and isolation requirements.
| Option | Typical | Advantage |
|---|---|---|
| Length | 1 / 2 / 4 km | Less staging, easier reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Flat bow / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and provides docs that lists final specifications for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item ships with recorded acceptance data.
Lab Testing: Heat, Salt Spray & Vibration
Our lab conducts elevated-temperature exposure, salt fog corrosion, and vibration tests to qualify materials and assemblies. These tests simulate field stresses for indoor and outdoor use.
100% test reports for every cable
Every fiber optic cable ships with a 100% test report that logs attenuation, return loss, and geometry where applicable. Final inspection gates stop nonconforming items before they leave the factory.
Traceability and compliance
Lot/batch records link tests to reels/serials so audits and warranty claims are simple to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- Line checks and final inspection prevent field failures and cut warranty events.
- Quality packages include spec confirmation and formatted test data for rapid review.
- Ongoing trend analysis drive preventive maintenance and raise long-term reliability.
| Trial | Why | Outcome |
|---|---|---|
| High-temperature | Material stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Qualified for outdoor use |
| Vibration | Resistance to vibration | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run begins with fiber/jacket selection and is refined by volume and customization.
Typical prices range broadly—from about $30 to $1,000 per unit—based on fiber grade, jacket chemistry (LSZH, PVC, PE), reel length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber grade, sheath material, and the chosen structure for deployment.
Self-supporting designs and steel strength elements increase material/labor. Custom colors, logos, and print legends add setup time and impact pricing on small runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders lower unit cost. Short runs often carry setup fees and higher per-unit charges.
- Line changeovers and custom tooling increase lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets across phases.
| Factor | Price impact | Recommendation |
|---|---|---|
| Fiber grade | Large | Right-size spec to budget |
| Sheath material | Medium | Evaluate LSZH vs PE |
| Order length / volume | High impact | Consolidate where possible |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable schedules cut downtime and control costs when a rollout is underway.
Scheduling & Capacity Planning
Typical production windows run 4–5 days for orders under 100 km and 7–10 days for orders under 500 km. We schedule line capacity to track your milestones and to maintain on-time delivery.
The service team issues production updates and tracking so installation teams can plan arrivals. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. This reflects line setup such as wire and jacket die adjustments that use startup material and generate scrap.
We review your length and staging plans to choose reel sizes that cut waste and handling. Batch releases can balance inventory with more frequent small-site deliveries.
Where and How to Deploy
On-site conditions determine whether a self-supporting span, ducted pull, or direct-buried run is the right choice for a project.
Aerial vs Duct vs Direct-Buried
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with appropriate members to manage sag/tension for long-term stability.
Duct installations work best with low-friction sheaths and crush-resistant constructs so pulling does not damage fibers. PE jackets are common for underground and buried paths where moisture resistance matters.
Direct-buried designs need correct burial depth per local codes and moisture barriers to protect the fiber core long-term.
Indoor Distribution and ONT
Indoor riser and plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop profiles strip clean and present controlled stubs for fast ONT terminations.
We guide the choice of steel or FRP (dielectric) strength members based on bonding requirements, lightning exposure, and hardware fit. Standardized line prep reduces install time and minimizes scrap.
| Deployment | Key design | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct burial | PE with moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH with tight-bend support | Maintain bend radius at wall penetrations |
Our approach delivers a consistent installation across indoor outdoor transitions. That reduces callbacks, speeds activations, and reliable field performance for your system.
Support from Spec to Service
Our team coordinates testing, scheduling, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements capture through approved drawings and pre-production builds. We deliver documentation templates and clear install notes so field crews work from the same plan.
After-sales service covers rapid response, root-cause analysis, and corrective actions. All products ship with full test reports and traceability to support QA acceptance.
- 24/7 availability for status updates and technical guidance.
- Warranty includes free replacement for confirmed quality issues.
- Coordination of line schedules for expedites and urgent changes.
- Config control so shipped items match agreed specs consistently.
| Area | Scope | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Reduced field issues |
| Testing | Lab trials & 100% test reports | Traceable quality |
| After-sales | Rapid replacement & root-cause | Lower downtime |
Conclusion
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We provide custom FTTH drops that combine materials with validated manufacturing and lab tests. Every reel includes a 100% test report and documented lab trials to support field acceptance in the United States.
A hardened production line, including CLX-BPO2 prep assets, reduces variability and speeds turnaround. Our equipment and machines standardize strip/stub lengths so installers get consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance design and cost to extend service life. Dedicated support guides scheduling, logistics, and after-sales care so your deployment remains on plan.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive support.